Carton set-up machine



'7 Sheets-Sheet 1 W. E. MEISSNER ET AL CARTON SET-UP MACHINE Feb. 26, 1957 Filed June 18, 1954 Feb. 26, 1957 W, E, MElsSNER ET AL, 2,782,695

CARTON SET-UP MACHINE Sheets-Sheet 2 Filed June 18, 1954 F670- 26, 1957 w. E. MEISSNER ETAL 2,782,695

CARTON SET-UP MACHINE Filed June 18, 1954 Feb.. 26, i957 w. E. MElssNER ETAL. 2,782,695

CARTON SET-UP MACHINE 7 Sheets-Sheet 4 Filed June 18, 1954 Feb. 26, 1957 W. E. MElssNER ET AL 2,782,695

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Feb 26, 1957 w. E. MElssNER ET AL 2,782,695

CARTON SET-UP MACHINE 7 Sheets-Sheet 7 Filed June 18, 1954 umanmnmmny United States Patent This invent-ion relates to packaging apparatus and, more particularly, to a machine for folding andsealing the liaps of4 cardboard cartons. s

The apparatus is particularlyv adapted to the sealing ofl cartons not only of card-board but of related materials such as hberboard, chipboa-rd, reinforced laminated cardf boards and the like, the iiaps of whichY are ordinarily sealed with a` thermoplastic adhesive material.v Prior practice has generally employed a( liquid adhesive for carton ap sealing. Such adhesive has the objection that it frequently does not set up fast enough toA enable satisfactory use Withhighspeed carton formi-ng or filling machines.

Various thermoplastic. type'materials are used as adhesives and are usually employed as a coating` on the surfaces or areas to be sealed.- Sealing is accomplished by the application of heat andpressure to the opposite surface to which. the thermoplastic coating is applied; For thinmaterials, such assheets of regenerated cellulose employed in making bags,4 this procedure is satisfactory and sealing is accomplished quickly. However, in the case of cardboard, and the like, such as employed in forming cartons,` a longer time is required for the heat to penetrate the cardboard, etc., and softe-n, the thermo plastic coating. on. 'the other surface suiflciently to give av goodlstrongv seal. The time required for suchheat penetration is excessive whenA dealing with high-speed automatic carton-forming or set-up machines.-

s It is a general object of the( present invention to pro; vide a method andy apparatus for heat-'sealing thick thermoplastic coated materials quickly and eiiciently sol as to produce a strong vseal a minimum amount of time;

It is another objectof the invent-ion to provide a method and apparatus for heatfseali-ngf thermoplastic coated carton flaps in such a manner that the same. may be.employed inV or in conjunction with high-'Speed automatic cartonfformi-ng mzvrchincs.v

It is a further object ofthe'v invention to provide a new method and apparatus for heat-sealing thermoplastic ti-lrns or thermoplastic coatedrnaterials;

Further objects will beapparent from the specification and drawings in which;

Figure l is a. side view of aV carton-s`ealing machine constructed in accordance with the present invention. partly sectioned andvwithg other parts; broken away for clarity;

Figure 2- isa top view of thestructure of Figure 1";V

Figure 3 is arr endview of the structure of Figure l.;

Figure 4V is an enlarged fragmentary detail of one.v of the heatingV ap folders;

Figure 5 is a sideview cfg the structure of Figulc 4:;

Figure 6 is an enlarged sectional: detail as seen at V'I-VI of Figure14;l

Figure 7 is a perspectivev showing the horizontal flap'- foldi-ng ram assembly and` pressure plate;

Figures 8-12 are fragmentary detailsillustrating` progressively the action of the ram assembly of Figure 7;

Figure 13 is a schematic View showing the various electrical and hydraulic actuating controls; and

Figure' .14 :is a timing. diagram Vfor the various moving parts.

Generally,` the objects of the present invention are accomplished `by yfirst coating the material to be sealed with a suitable thermoplastic coating composition by any known conventional method. A heated metal plate, tongue, or shoe is brought Vin contact with the coated surfaces to be sealed, thus heating the thermoplastic coating. vSuitable pressure may then be applied to complete the sealing operation. While the present invention is applicable to the sealing. of any type material made from a thermoplastic substance or having a thermoplastic coating on the surface thereof, for simplicity the invention will be illustrated and Idescribed as it is generally applicable to the sealing of shipping' containers or cartons, such as those made' from cardboard and the like;

The at carton blanks withV only the sides 'sealed 'ar'e individually fed to a sealing station where they are opened up or squared by means of a pivoting gate supplied with suction cups. While oppositely moving pressure heads or rams are directed towards one end of the squared carton, a pair of heated blades foldl the inside aps to their sealed position against one of the rams, whereupon the other ram folds the outside llaps over the heated blades and presses the aps together suiciently long to effect a heating`V of the adhesive on the flaps. Before final sealing. pressure is applied, the pressure o'n the outside ram is removed for a time sufficiently long to permit withdrawal of the hot blades, whereupon the outside ram is re-actuated to compress the tiap's against the inner ram' and complete the seal.

All of the abov'e operations take place continuously and sequentially without interruption', the unsealed cartons being conveyed along a path to the sealing` position one after another. The apparatus, hereinafter described in detail, is capable of sealing cartons of varying sizes. In addition, the .method and apparatus may be employed toseal cartons which have already been packed.

Referring now" more particularly to the drawings, a preferred form of the apparatusv comprises a generally horizontal feed table assembly comprising a stationary hopper 21 in which at carton blanks C are loaded. The feed table assembly is supported on a suitable framework including posts or columnsr 22, 22. Individual cartons are withdrawn from the bottom of the carton stack in hopper 21 by means of a reciprocating plate 23 actuated back and; forth across the' table b'y means of a uid cyl inder 24; which is' connected fo a bracket` 25 on plate 23 through: a piston rodl 26;l The folded carton blanks are advanced toa set-up station on' table 30 as Shown in Figures l and! 2. This table is provided with one or more suction cups" 31 and 3-2- to retain the bottom of the carton on table 3,0. in proper position while the" carton is opened. With the flat carton blank in proper place on table 30. platev 23 is retracted and a pivoting plate or gate 33 swings down tothe' position shown in Figure l on top of the. flat carton. Gate 33 is likewise provided with a pair of suction cups or elements 34 and 35 so that when it is pivoted' upwardly in a counterclockwise direction, as shown in Figure l, the cartonY is squared on table 30. Wheny the flaps on one end of the carton have been sealed, as: will be described hereinafter, gate 33 continues' fo pivot in a counter'clockwse direction to carry the carton around' with it after suction has been released in cups 31 and 32. Continued turning ofthe gate-33 to the dotted line position shown at 3-3b in Figure 1 completely discharges the carton from the apparatus and onto a chute or other suitable receiver when the vacuum is released in thecups 34 and 35. The actuating mechanism for gate 33 comprises a crank 40 journaled in a bracket 41' mountedont-he framework assembly. The crank a'r'm is connected to gate 33 by means of a clip 42 to control the movement of gate 33 around hinge 43. The opposite l end of the crank 40 is actuated by means of a rack 44 and a pinion 45 which are in turn controllable through a fluid pressure cylinder 46. A releasable latch 47 is mounted on post'48 of the framework to insure proper registry of gate 33 when in the set-up position, since it is important that the carton be substantially square to permit proper actuation of the other apparatus.

When the carton C has been opened or squared to the position shown in Figures 1 and 3, a duid cylinder assembly 49 is automatically controllable to advance a pressure head 50 into the open end of the carton from the left as seen in Figure 3. During this operation the carton body is securely held in place by means of the suction cups 31, 32 and 34, 35. Simultaneously, the pressure head 51 is advanced by cylinder 52 mounted on framework 53 to slightly open the vertical carton flaps 54 and 54. This action is shown clearly in Figure 10. With the vertical flaps slightly sprung outwardly, it is then possible to fold or bend the horizontal inner flaps 56, 56 to their sealed positions without danger of interference from the edges of the side ilaps. For this purpose, we use a pair of heated blade assemblies 57, 58 which are respectively mounted and controlled by blade housings 59 and 60. The upper housing S9 is pivotally supported on cross frame member 61 and 62, whereas the lower blade assembly is mounted in trunnions 63, 63.

Referring now to Figures 4-6, an important feature of the invention resides in the provision of the heated blades and their associated structure. The blade housings are alike so that a description of the upper housing such, for example, as shown in Figure 4 will suffice for both. The blade proper 70 is movable into and out of the housing 59 to enable it to be heated and also to provide for the flap turning function. The blade extends inside the housing in a generally bifurcated manner having guide arms 70a and 70h which vare carried in rollers 71, 71. A piston rod 72 is secured to the blade 70 between arms 70a and 70h, and the opposite end of thepiston rod is actuated by a conventional uid pressure cylinder 73. In this way, it will be apparent that the blade itself is capable of vertical reciprocal movement when ,actuated by cylinder 73. Piston rod 72 carries a roller 75 which extends through a slot 76 in the housing 59. This roller runs along a track 77 (Figures 1 and 3) which is suitably supported by brackets and cross members 78 and 79 secured to posts 80 and 81.

Housing 59, as noted above, is pivoted in cross members 61 and 62 by bearings or trunnions 85, 85. A spring 86 biases the housing so that the roller 75 is maintained in spring-loaded contact with the track 77; When `the blade 70 is extended, it will be noted that the downward or upward travel, as the case may be, is substantially in astraight line for a short distance. This is to start the bending of the inner flaps 56, 56 of the carton at a p oint substantially spaced from their bend line. However, as the blade continues to advance, track 77 curves towards the blade housing so that the housing pivots on'bearings 85, 8S to turn the ap through an arc of substantially 90. The housings 59 and 60 are'provided with side members 90, 91 in which the rollers` 71 are journaled. Four heating elements 92, 92 are suspended from the housing cover- 93 as shown in Figures 4 and 6. Y Suitable insulation 94, 94 reduces heat dissipation from heaters 92, 92. Also, we provide a pair of spring-loaded Scrapers 95, 95 to remove any adhesive or other matter which might be retained on the blade and thus cause sticking'. 'The construction of both the upper and lower blade housings is identical, and, therefore, duplicate description is .believed to' be unnecessary. The reference numerals for the lower housing 60 are used for corresponding parts but with primed numbers. Also, it will be understood that the heated blade flap folders maybe used horizontally as well as vertically as shown.

' The back-up ram 50 is mounted on a shaft or piston 4 rod which is actuated by uid cylinder 49. The ram head or pressure plate 50 is substantially the same configuration as the hollow cross-sectional area of carton C, and this assembly is supported in framework 101 in alignment with the open end of the squared cartons C. As soon as the carton is squared, ram head 50 advances into the carton, until it has substantially reached a fully extended position in which the forward face of the ram is approximately in line with the bend lines in the opposite end of the carton. As noted previously, the carton is maintained in accurate registration by means of the suction cups in the gate and the table.

The opposite pressure ram head 51 serves a dual purpose in that it not only controls the aps before they are heated but it also applies final sealing pressure. Referring to Figures 7-l2, ram head 51 comprises a pressure plate 102 having attached on its face a pair of arcuate spring arms 103 and 104. The extremities of these arms are provided with small springs 10S and 106 having a plate across the U-shaped portion of each spring. After the carton is positioned at the set-up station and squared by means of gate 33, cylinder 52 is energized to advance the ram head 51 and its associated spring structure. Figure 8 illustrates the position of the ram head and structure just before making contact with the carton aps. Figure 9 shows initial engagement between the at springs 103 and 104 and the side carton aps 54, 55. Further forward movement of the ram 51 opens the carton aps 54, 54 slightly as shown in Figures 9 and l0, thus insuring that the upper tiaps 56, 56 clear the edges of the side flaps when folded inwardly. As soon as theaps 54, 55 are moved out of the way, the heated blades 70 and 70 are advanced to engage the inner aps 56, 56 and fold them inwardly against the ram 50. Such a position of themechanism is shown in Figure 10 in which the upper blade 70, shown in section has completely folded one of the upper flaps 56 against the ram to heat the adhesive on the ap. As soon as this operation has been completed, ram 51 continues to advance and in so doing the flaps 54, 54 slide olf of or out of engagement with the springs 105, 106.

Figure 11 shows one of the side aps after it has become disengaged from the spring 105. Continued advancing of the head 51 folds the side flaps against the hot blade 70 and compresses both the inner and outer flaps against the blade through the cooperation of ram 50 until the adhesive on the flaps is adequately heated. The pressure on head 51 is then momentarily released so that both blades 70 and 70' can be withdrawn from between the aps. Pressure is then reapplied to head 51 to press the aps against each other and complete the pressure seal, whereupon both the rams 50 and 51 are retracted to permit the carton to be removed from the set-up station by means of gate 33.

In Figures 8-12, we have illustrated only one side of the ram head 51 comprising plate 102, springs 103, and 105. It will be understood that the opposite side of the ram head assembly operates in an identical manner so that the descriptionwith regard to spring 105 applies equally to spring 106.

A more detailed description of the actuating and coordinating mechanism for the various sub-assemblies described above will be apparent from a reference to Figures 13 and 14 in which the timing sequence is more clearly shown. The hydraulic system shown in full lines in Figure 13 comprises a pump 110 connected to a uid supply reservoir 111. Both uid cylinders 73 and 73 are controlled by means of a solenoid-actuated valve assembly 112. Cylinder 52 is controlled by means of a similar solenoid-actuated valve 113 as are iuid cylinders 24 and 46 by means of valves 114 and 115 respectively. The gate stop latch 47 is electrically controlled as will be more fully described hereinafter, and the stop latch 1,16 for ram head 51 is likewise electrically controlled. The table suction elements 31 and 32 are controlled through solenoid-actuated valve 117, and the gate suc,

tion elements 34 and 35 are similarly controlled' lthrough a solenoid valve 118. The main suction supply conduit 120 connects a source of low pressure air or iiuid (not shown) to the various suction elements 31, 32,134-, 35 by means of conduits Y121 and 122. The .backmp` ram actuating cylinder 49 is controlled similarly vto cylinders 24, 46 and 52 through a solenoid-actuated hydraulic valve 125.

The timing mechanism for operating all `the various moving parts of the machine, either directly through electrical mechanism or indirectly through solenoid-actuated iuid valves, comprises a timing cylinder or drum 130 journaled at 1.31,V 132 andv driven at a slow constant speed by motor 133. Current from a power source 134 is carried through conductor and brush 135 to a common segment 136 on the drum 130. Segment 136 is connected to the various separate segments S, S on the periphery of the drum so that the individual circuits are completed when contact occurs between the segments S, S and brushes B, B which are in turn connected to the various solenoidwindings described above. The construction of such solenoids and solenoid-actuated vvalves is well-known in the art and forms no part of the present invention. Also, it will be understood that` we have chosen to describe and illustrate a timing mechanism capable of providing the desired sequential operation of the various elements of the machine. Any other meansl for accomplishing this result may, of course, be employed within the scope of the invention. Since the timing of the various elements is critical, however, a chart has been prepared to indicate how they are cooperatively arranged to accomplishv the desired result. The abscissae in Figure 14 represent degrees` of rotation of cylinder 130.; and when adjusted to handle a complete carton in l seconds, the relative time at which each operation. takes place can be determined directly from the scale at the top of the graph.

At the indicated Vstarting position of cylinder 130 shown as zero degrees on the graph', the gate suction, controlled by valve 118, is operative to" hold the carton on the gate preparatory to being discharged therefrom. kAt this point cylinder 24 is actuated by closing of the con tacts associated with the solenoid in valve 114. This in turn moves one flat carton blank from the bottom of the stack in hopper 21 to the folding station on table 30. Meanwhile, the gate suction has been closed to permit the carton on the gate to fall onto chute 36. At about 40 the gate 33 is turned in a clockwise direction, as seen in Figure 1, by retraction of rack 44 within cylinder 46. This positions the gate on top of the folded carton blank which has just been delivered to table 30. At about 67 both the table suction and the gate suction are applied by energization of valves 117 and 11S. With suction still applied, valve 115 is de-energized at 90 so that rack 44 is expelled from cylinder 46. However, the gate 33 remains in a vertical position since it is held by latch 47. It will be understood in this connection that the latch permits clockwise rotation of the gate but will not permit the gate to pass when turned in a counterclockwise direction until the latch is released. At about 123 ram heads 50 and 51 are both actuated. Ram 50 advances into the carton until it is approximately opposite the bend lines for the llaps at the opposite end. Ram head 51 continues to advance until it is held by latch 116. During this portion of its travel, it has served to spread the vertical outer carton flaps 54 and 54 as described previously. At about 150 cylinders 73 and 73 are energized to fold the inner iiaps against ram head 50. When these have been sufficiently folded, the latch 116 for ram head 51 is released at 180, thus permitting ram head 51 to continue its advance and press the iaps against the heated blades 70 and 70. At 258 the pressure on ram head S1 is released and valve 112 is de-energized, thus permitting withdrawal of blades 70 and 70', but before ram 51 retracts far enough to engage ylatch .116, it againadvance'd- .when `contact. isnmade at about 27.5. Thi'sl advances ram head- .51 against the folded carton. flaps, and squeezes them-between the' I'Jlz'itev 102 and the ram Ihead 50"to pressure seal V.the naps. At about 330 contact for both raml val-ves isi opened `so that vthey retractftotheir initial positions. Theny the table suction is removed lby opening of the circuit to table suction valve 117;. and, simultaneonsly, latchf47 is released, thus permitting the gate with gate suction'ap'plied to pivot to vthe discharge position shown. at 33b' in 'Figure l. This completes the operating cycle lofv the apparatus'.

`One of the important` features of thepre'sent invention is' the; bringing of a heated element into direct contact with the thermoplastic coating, heating the coating quickly and then withdrawing the heated element and then applying pressure to the' material" to effect the seal. The seals thus produced are uniform and strong and sealing isA accomplished quickly without the necessity of having to heat the coating. through the base material to which it is1appli`edlwhiehz is tirneconsuniing.

It is to be notedv that the' sealing shoes or tonques can be shaped to seal or' heat any` desired area leaving nnsealed surfaces forv use in; easy opening or other purposes. In addition, the thermoplastic coating may be applied te any desired area. Packages' or cartons sealed in accordance: withl the present invention vare immediately suitable for haudlingsinceno gluesor liquid adhesives are employed which require time for drying. Itis this appiication that makes thel present invention particularly advan tageou's forhigh-speed automatic set-up box or carton machinery since 'thel seal i's` triade almost instantaneously.

. By' means or? the present invention, vit is possible to seal several eartsisper minute-and; in addition, all messy glue pots, glu'e` applicators, lmetal stitching machines',- etc.,- are eliminated. The thermoplastic material er coating may be p'ut the 'carton flaps`y when the carton blanks are' formed; by the manufacturer. 1

When` attempts 'we're made to pull apart' the'- seals` made in accordance with the present invention, the cardboard tore; r'athe'r than the seal or bond-Y breaking loose.l Seals Were checked Vunder"'92% relative humidity" conditions and found' to be'excellenrin all' respects'. It will be apparent from the description of the present method and apparatus that the invention is easily adapted for sealing the open end of the carton after insertion, mechanical or otherwise, of the material to be packed therein. Numerous other advantages of the present invention will be apparent to those skilled in the art.

As many possible embodiments may be made of the mechanical features of the present invention and as the process may be varied in various aspects, all without departing from the spirit and scope of the invention, it

is to be understood that all matter hereinabove set forth` or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

Having thus described our invention, we claim:

1. A carton set-up assembly comprising a horizontal table, means associated with said table for moving at cartons from a supply to a set-up station at one end of said table, a suction element in the table at said set-up station, a pivoting plate hinged at one end of the table adjacent the set-up station, a suction element on said pivoting plate, means for pivoting the plate through an arc substantially more than 180 from a position overlying the set-up station, latch means for selectively retaining the plate in a position with respect to the table, and means for sequentially actuating the fiat car ton advancing means, the plate pivoting means, the suction means and the latch means whereby a at carton is conveyed to the set-up station, squared and removed from the station.

2. A carton set-up assembly comprising a horizontal table, means associated with said table for moving at cartons from a supply to a set-up station at one end of said table, a suction element in the table at said set-up station, a pivoting plate hinged at one end ofthe table adjacent the set-up station, a suction element on said pivoting plate, means for pivoting the plate vthrough an arc substantially more than 180 from a position overlying the set-up station, latch means for selectively retaining the `plate in a 90 positionwith respect` to the table, meanspfor sequentially actuating the flat carton advancing means, the plate pivoting means, the suction means and the latch means whereby a tlat carton is conveyed to the set-up station, squared and removed from the station, a hap-folding pressure head, means for advancing said pressure head, resilient ap control members attached to said head for initially spreading and subsequently folding the outer carton aps in pressure contact therewith, and a pair of retractable blades for folding the inner flaps in advance of the outer aps.

3. A carton set-up assembly comprising a horizontal table, means associated with said table for moving tlat cartons from a supply to a-set-up station at one end of said table, a suction element in the table at said set-up station, a pivoting plate hinged at one vend of the table adjacent the set-up station, asuction element on said pivoting plate, means for pivoting the plate through an arc substantially more than 180? from a position overlying the set-up station, latch means for selectively retaining the plate in a 90 position with respectl to the table, means for sequentially actuating 4the at carton advancing means, theiplate pivoting means, the suction means and the latch meansl whereby a llat carton is conveyed to the set-up station, squared and 'removed from the station, a flap-folding pressure head, means for ade vancing said pressure head, resilient ap controlv members.4 attached to said,head ,forinitia1ly'spreading and subsequently folding the outerrcartonvaps in pressure contact therewith, a pair of ,retractable bladesfo'r folding the inner ilaps in advance of the outer aps, aback-up ram advanceable into one end of the `carton for cooperating with the pressure head, and means-.for advancing and retracting said back-up ram.

4. Apparatus in accordancewith claim 3 having means for interrupting the movement of the pressure head advancing means to permit folding of the inner flaps.v

5. Apparatus in accordance with claim 4 having means for heating the retractable blades.

6. Apparatus in accordance with claim 3 in which the sequential actuating means comprises a source of fluid pressure, a separate uid cylinder operatively connected to the fiat carton advancing means, the gate, the plate pivoting means, the back-up ram, the pressure head, a solenoid controlled valve for each of said liuid cylinders, a source of electrical current, and means including a timing cylinder for sequentially energizing the solenoid valves.

7. In a carton set-up machine, the subcombination that comprises a nap-folding pressure head, means for advancing and retracting said pressure head, a resilient curved member secured to the face of said pressure head, and resilient means secured to said member for engaging `and controlling the position of a carton flap as the pressure head advances.

8. Apparatus in accordance with claim 7 in which the resilient curved member comprises two forwardly concave at springs secured to the pressure head, and the resilient means comprises a spring-biased flap mounted adjacent the extremities of the springs to initially spread the aps and thence to yieldingly close the flaps as the ram advances.

9. In carton set-up machinery, the subcombination that comprises a flap-folding blade housing, a blade reciprocably mounted in said housing, means secured to the housing for advancing and retracting the blade with respect to the housing, a pivotal support for said housing, and control means connected to the blade for pivoting the housing and blade on the support as the blade is advanced with respect to the housing. Y

l0. Apparatus in accordance with claim 9 having a spring for biasing the housing towards a pivoted position.

Ferguson Apr. 28, 1942 Ardell July 14, 1942 

